Power Pro (Glt) 3500 User Manual GENERATOR Manuals And Guides L0522015

POWER PRO (GLT) Generator Manual L0522015 POWER PRO (GLT) Generator Owner's Manual, POWER PRO (GLT) Generator installation guides

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MODEL 3500
6.5HP Generator
Item # 56350
Owner's Manual
Manual del Propietario
DO NOT RETURN TO STORE
Questions? Problems?
Please call our customer help line:
(888) 315-3080 M-F 84 CT
Thank you for purchasing a model 3500 generator. This manual provides information regarding the
operation and maintenance of this product. We have made every effort to ensure the accuracy of
the information in this manual. Wen Products reserves the right to change this product at any time
without prior notice.
Please keep this manual available to all users during the entire life of the generator.
rev. O1/21/05
MODEL 3500
6.5 HP Generator
FEATURES
•3500 Surge Watt Output
•3000 Rated Watt Output
•Powerful Enough to Run Essential Appliances
During Power Outages
•120 and 240 VoltAC Outputs
•DC Output for Automotive Battery Charging
•Low OilAutomatic Shutoff
•Circuit Breaker for Overload Protection
•4 Gallon Fuel Tank Capacity
•Easily Portable- less than 100 lbs
•Meets EPA and CARB emissions standards
TABLE OF CONTENTS
GENERAL SAFETY PROCEDURES ........................................................................ 4
PACKAGE CONTENTS ....................................................................................... 8
GENERATOR COMPONENTS .............................................................................. 9
PREPARING THE GENERATOR FOR USE ............................................................... 10
Using the Generator for the First Time ............................................................... 10
Step 1- Add Oil ................................................................................. 10
Step 2- Add Gasoline .......................................................................... 11
Step 3- Ground the Generator ................................................................ 11
Subsequent Use of the Generator ..................................................................... 12
Step 1- Check the Oil .......................................................................... 12
Step 2- Check the Gas Level ................................................................. 13
Step 3- Ground the Generator ................................................................ 13
STARTING THE GENERATOR .............................................................................. 14
USING THE GENERATOR ................................................................................... 15
AC Usage ................................................................................................ 15
DC Usage ................................................................................................ 17
STOPPING THE GENERATOR .............................................................................. 18
MAINTENANCE /CARE ..................................................................................... 19
Cleaning the Generator ................................................................................. 19
Changing the Oil ........................................................................................ 19
Changing/Adding Oil .................................................................................. 20
Air Cleaner Maintenance .............................................................................. 21
Fuel Filter Cup Cleaning .............................................................................. 22
Spark Plug Maintenance ............................................................................... 22
Emptying the Gas Tank ................................................................................ 23
STORAGE / TRANSPORT PROCEDURES ............................................................... 23
SPECIFICATIONS .............................................................................................. 24
TROUBLESHOOTING ......................................................................................... 25
EXPLODED VIEW AND PARTS LIST ..................................................................... 26
WIRING DIAGRAM ........................................................................................... 28
Notice Regarding Emissions
Engines that are certified to comply with California and U.S. EPA emission regulations
for SORE (Small Off Road Equipment), are certified to operate on regular unleaded
gasoline, and may include the following emission control systems: (EM) Engine
Modifications and (TWC) Three-Way Catalyst (if so equipped).
GENERALSAFETYPROCEDURES
Please familiarize yourself with the following safety symbols and words:
The safety alert symbol A is used with one of the safety words (DANGER, CAUTION,
or WARNING) to alert you to hazards. Please pay attention to these hazard notices both
in this manual and on the generator.
DANGER: Indicates a hazard that will result in serious injury or death if instructions are
not followed.
WARNING: Indicates a strong possibility of causing serious injury or death if
instructions are not followed.
CAUTION: Indicates a possibility of personal injury or equipment damage if instructions
are not followed.
{WJ_ If you have any questions regarding the hazard and safety notices listed in this
manual or on the product, please call (888) 315-3080 M-F 8-5CT before using the
generator.
ADANGER: This generator produces poisonous carbon monoxide gas when
running. This gas is both odorless and colorless. Even if you do not see or smell
gas, carbon monoxide may still be present. Breathing this poison can lead to
headaches, dizziness, drowsiness, and eventually death.
• Use outdoors ONLY in non-confined areas.
• Keep several feet of clearance on all sides to allow proper ventilation of the
generator.
AWARNING: The exhaust from this product contains chemicals known to the
State of California to cause cancer, birth defects, or other reproductive harm.
AWARNING: This generator may emit highly flammable and explosive gasoline
vapors, which can cause severe burns or even death. A nearby open flame can lead
to explosion even if not directly in contact with gas.
• Do not operate near open flame
• Do not smoke near generator.
• Always operate on a firm, level surface.
• Always turn generator off before refueling. Allow generator to cool for at least 2
minutes before removing fuel cap. Loosen cap slowly to relieve pressure in
tank.
• Do not overfill gas tank. Gas may expand during operation. Do not fill to the top
of the tank.
• Always check for spilled gas before operating.
• Empty gasoline tank before storing or transporting the generator..
• Before transporting, turn fuel valve to off and disconnect spark plug.
WARNING: This generator produces powerful voltage, which can result in
electrocution.
•ALWAYS ground the generator before using it (see the "Grounding the
Generator" portion of the "PREPARING THE GENERATOR FOR USE"
section).
• Generator should only be plugged into electrical devices, either directly or with
an extension cord. NEVER connect to a building electrical system without a
qualified electrician. Such connections must comply with local electrical laws
and codes. Failure to comply can create a backfeed, which may result in serious
injury or death to utility workers.
• Use a ground fault circuit interrupter (GFCI) in highly conductive areas such as
metal decking or steel work. GFCIs are available in-line with some extension
cords.
• Do not use in rainy or wet conditions.
• Do not touch bare wires or receptacles (outlets).
• Do not allow children or non-qualified persons to operate.
A WARNING: This generator produces heat when running. Temperatures near
exhaust can exceed 150°F (65 ° C).
• Do not touch hot surfaces. Pay attention to warning labels on the generator
denoting hot parts of the machine.
• Allow generator to cool several minutes after use before touching engine or areas
which heat during use.
CAUTION: Misuse of this generator can damage it or shorten its life.
• Use generator only for its intended purposes.
• Operate only on dry, level surfaces.
• Allow generator to run for several minutes before connecting electrical devices.
• Shut off and disconnect any malfunctioning devices from generator.
• Do not exceed the Wattage capacity of the generator by plugging in more
electrical devices than the unit can handle (see "PRECAUTIONS-
OVERLOADING THE GENERATOR").
• Do not turn on electrical devices until after they are connected to the generator.
• Turn off all connected electrical devices before stopping the generator.
In additionto theabovesafetynotices,pleasefamiliarizeyourselfwith thesafetyand
hazardmarkingsonthegenerator.
N
PACKAGE CONTENTS
Your generator comes with the items listed below. Please check to see that all of the
following items are included with your generator.
OIf you are missing components DO NOT RETURN TO STORE, please call
(888) 315-3080 M-F 8-5 CT for customer service.
ITEM LIST
NEMA L14-30 plug for connecting 240 Volt electrical devices
i ZZ !i_¸
Three-prong plug for connecting 120 Volt electrical devices
Set of 2 DC connector wires for connecting 12 Volt automotive-
type batteries
Spark plug wrench
GENERATOR COMPONENTS
Please familiarize yourself with the locations and functions of the various components
and controls of your generator.10
3
2
5
(1) Air cleaner- a removable, cleanable, sponge-like
element that limits the alnount of dirt pulled into the
engine.
(2) 120 Volt AC Receptacle- Use to connect
electrical devices that run 120 Volt, 60 Hz, single
phase, AC current.
(3) 120/240 Volt AC Receptacle- Use to connect
electrical devices that mn 120 and/or 240 Volt, 60
Hz, single phase, AC current.
(4) 12 Volt DC Receptacle- Use for charging 12
Volt automotive-type batteries only.
(5) Circuit Breaker- Reset switch that protects the
generator from electrical overload.
(6) Choke lever- Adjusts the amount of air let into
the engine.
I G
(7) Engine Switch- Used to start/stop engine.
(8) Fuel Cap- Access to the fuel tank for adding fuel.
(9) Fuel Filter (;up- Traps dirt and water fioln fuel
before it enters the engine.
(10) Fuel Gauge- Indicates the amount of fuel in the
tank.
(11) Fuel valve- Allows fuel to enter engine.
(12) Ground Terminal- Connect grounding wires here
to properly ground unit.
(13) Muffler- Reduces engine noise.
(14) Oil Fill and Dipstick- Location for checking and
filling engine oil.
(15) Recoil Starter- Pull-cord for starting engine.
(16) Spark plug- Provides proper engine ignition.
(17) Volt Meter- Provides reading of voltage output.
PREPARING THE GENERATOR FOR USE
Using the Generator for the First Time
QThe following section describes steps you must follow to prepare your generator
for first-time use. If after reading this section, you are unsure about how to perform
any of the steps please call (888) 315-3080 M-F 8-5 CT for customer service.
Failure to perform these steps properly can damage your generator or shorten its life.
If you are using the generator for the first time, there are a few steps you must take to
prepare it for operation:
Step 1- Add oil
The generator requires engine oil to operate properly. The generator, when new from the
package, contains no oil in the crankcase. You must add the proper amount of oil before
operating the generator for the first time. This amount, which is equal to the oil capacity
of the engine crankcase, can be found on the chart in figure 1. When filling the engine
with oil in the future, please refer to this chart.
Figure 1- Generator Oil CapaciD _
Model number 2200 3500 5500
Engine oil 20 fluid oz. 20 fluid oz. 37 fluid oz.
capacity
To add oil, follow these steps:
1. Make sure the generator is on a level surface.
2. Unscrew the oil filler/dipstick cap from the engine as shown in figure 2.
3. Using a funnel, add the appropriate amount ofoil, as found in figure 1, into the
crankcase. You will know the crankcase is full when the oil level has reached the
lower lip of the opening you have just poured the oil into (see figure 3).
4. Replace oil filler cap.
O_ FLLER HOLE
Ott, _q_.LER CAP ?
Figure 2- Unscrewing the oil cap Figure 3- Adding oil
10
Step 2- Add Gasoline
WARNING: Gasoline and gas fumes are highly flammable.
•Do not fill tank near an open flame.
•Do not overfill. Always check for fuel spills.
To ensure that the generator runs smoothly use only FRESH, U2qLEADED GAS WITH
AN OCTANE RATING OF 87 OR HIGHER. To add gasoline:
1. Make sure the generator is on a level surface.
2. Unscrew gas cap and set aside (NOTE: the gas cap may be tight and hard to
unscrew).
3. Slowly add unleaded gasoline to the fuel tank. Be careful not to overfill. Please
refer to the chart in figure 4 to find the gas capacity of your generator model. The
fuel gauge on the top of the generator indicates how much gasoline is in the
generator gas tank. NOTE: Gas can expand. Do not fill the gas tank to the very
top.
4. Replace fuel cap and wipe up any spilled gasoline with a dry cloth.
IMPORTANT:
• Never use an oil/gasoline mixture.
• Neveruse old gas.
• Avoid getting dirt or water in the fuel tank.
• Gas can age in the tank and make it hard to start up the generator in the future.
Never store generator for extended periods of time with fuel in the tank.
Figure 4- Gas Tank Capacity
Model number 2200 3500 5500
Gas tank 15 L (3.96 gallons) 15 L (3.96 gallons) 25 L (6.60 gallons)
capacity
Step 3- Ground the Generator
AWARNING: Failure to properly ground the generator can result in
electrocution.
Ground the generator by tightening the grounding nut against a grounding wire (see
figure 5). A generally acceptable grounding wire is a No. 12 AWG (American Wire
Gauge) stranded copper wire. This grounding wire should be connected at the other end
to a copper or brass grounding rod that is driven into the earth.
Grounding codes can vary by location. Please contact a local electrician to check the
grounding regulations for your area.
11
i' i!
j A
Figure 5- Attaching the Grounding Wire to the Generator
Subsequent Use of the Generator
If this is not your first time using the generator there are still steps you should take to
prepare it for operation.
IMPORTANT: At this point you should be familiar with the procedures described
in the first portion of this section entitled "Using the Generator for the First Time."
If you have not yet read this section, go back and read it now.
Step 1- Check the Oil
The generator is equipped with an automatic shutoff to protect it from damage due to low
oil. Nonetheless, you should check the oil level of the engine before each use to ensure
that the engine crankcase has a sufficient amount. To check the oil level:
1. Make sure the generator is on a level surface.
2. Unscrew the oil filler/dipstick cap.
3. With a dry cloth, wipe the oil off of the stick on the inside of the cap.
4. Insert the dipstick as if you were replacing the cap and then remove again. There
should now be oil on the stick. If there is no oil on the stick, or oil only at the
very end of the stick, you should add oil until the engine crankcase is filled (see
"Adding Oil" portion of the "Maintenance" section).
5. Be sure to replace cap when finished checking oil.
NOTE: The oil capacity for your generator can be found in the "Specifications" section
of this manual
12
Step 2-Check the Gas Level
Before starting the generator, check to see that there is sufficient gasoline in the gas tank.
The fuel gauge on top of the generator will indicate the gas level in the tank. Add gas if
necessary according to the steps in the "Adding Gasoline" portion of the "Maintenance"
section.
A WARNING: Gasoline and gasoline fumes are highly flammable.
• Do not fill tank near an open flame.
• Always allow engine to cool for several minutes before refueling.
• Do not overfill (check the "Specifications" section for the tank capacity of
your generator). Always check for fuel spills.
IMPORTANT:
• Use only U2qLEADED gasoline with an octane rating of 87 or higher.
• Do not use old gas.
• Never use an oil/gasoline mixture.
• Avoid getting dirt or water in the fuel tank.
• Never store generator for extended periods of time with fuel in the tank.
Step 3- Ground the Generator
A WARNING: Failure to properly ground the generator can result in
electrocution.
Ground the generator by tightening the grounding nut against a grounding wire (see
figure 5). A generally acceptable grounding wire is a No. 12 AWG (American Wire
Gauge) stranded copper wire. This grounding wire should be connected at the other end
to a copper or brass grounding rod that is driven into the earth.
Grounding codes can vary by location. Please contact a local electrician to check the
grounding regulations for your area.
13
STARTING THE GENERATOR
OBefore starting the generator, make sure you have read andperformed the steps in
the "Preparing the Generator for Use" section of this manual. If you are unsure about
how to perform any of the steps in this' manual please call (888) 315-3080 M-F 8-5
CT for customer service.
A CAUTION: Disconnect all electrical loads from the generator before attempting
to start.
To start your generator, perform the following steps:
1. Make sure no electrical devices are connected to the generator. Such devices can
make it difficult for the engine to start.
2. Check that the generator is properly grounded (see page 13, "Ground the
Generator").
3. Turn the fuel valve to the "on" position (see figure 6).
4. Move the choke lever to the "closed" position (see figure 7).
5. Set the engine switch to the "on" position.
6. Pull on the recoil starter handle slowly until a slight resistance is felt (see figure
8). Then pull quickly to start the engine. Return cord gently into the machine.
Never allow the cord to snap back.
7. If engine fails to start, repeat step 4. NOTE: After repeated attempts to start the
engine, please consult the troubleshooting guide before attempting again. If
problems persist please call (888) 315-3080 M-F 8-5 CT.
8. Once the engine has started and run for about a minute, move the choke lever
about half way towards the "open" position. Wait another 30 seconds and then
move the choke lever all the way to the "open" position.
9. Allow the generator to run for several minutes before attempting to connect any
electrical devices.
OFF
ON
Figure 6- Fuel Valve in the "on" position
STARTER GRiP
/
//
#
Models 2200 and 3500
CHOKE LEVER
CLOSBD ORE[N
Figure 7- Choke in the closed position
page 9 for choke location)
refer to
Figure 8- Pulling the start cord
14
USING THE GENERATOR
Once you have allowed the engine to run for several minutes, you may connect electrical
devices to the generator.
AC Usage
You may connect electrical devices running on AC current according to their wattage
requirements. The chart in figure 9 shows the rated and surge wattage of your generator
according to its model number.
The rated wattage corresponds to the maximum wattage the generator can output on a
continuous basis.
The sul\qe wattage corresponds to the maximum amount of power the generator can
output for a short period of time. Many electrical devices such as refrigerators require
short bursts of extra power, in addition the rated wattage listed by the device, to stop and
start their motors. The surge wattage ability of the generator covers this extra power
requirement.
Model Number Rated(Running)Wattage Surge Wattage
2200 1800 2200
3500 3000 3500
5500 5000 5500
Figure 9- generator wattage by model number.
The total running wattage requirement of the electrical devices connected to the generator
should not exceed the rated wattage of the generator itself. To calculate the total wattage
requirement of the electrical devices you wish to connect, find the rated (or running)
wattage of each device. This number should be listed somewhere on the device or in its
instruction manual. If you cannot find this wattage, you may calculate it by multiplying
the Voltage requirement by the Amperage drawn:
Watts = Volts x Amperes
If these specifications are not available you may estimate the Watts required by your
device by using the chart in figure 10.
Once you have found the rated wattage requirement of each electrical device, add these
numbers to find the total rated wattage you wish to draw from the generator. If this
number exceeds the rated wattage of the generator, DO NOT connect all these devices.
Select a combination of electrical devices, which has a total rated wattage lower than or
equal to the rated wattage of the generator.
CAUTION- The generator can run at its surge wattage capacity for only a short
time. Connect electrical devices requiring arated (running) wattage equal to or less
15
than the rated wattage of the generator. Never connect devices requiring arated
wattage equal to the surge wattage of the generator.
tool or appliance rated (running) Watts additional surge Watts
electric water heater (40 gal) 4000 0
hot plate 2500 0
saw- radial arm 2000 2000
electric stove 1500 0
saw- circular 1500 1500
air compressor (1 HP) 1500 3000
window air conditioner 1200 1800
saw- miter 1200 1200
microwave 1000 0
well water pump 1000 1000
reciprocating saw 960 1040
sump pump 800 1200
refrigerator freezer 800 1200
furnace blower 800 1300
computer 800 0
electric drill 600 900
television 500 0
deep freezer 500 500
garage door opener 480 0
stereo 400 0
box fan 300 600
clock radio 300 0
security system 180 0
dvd player/vcr 100 0
common light bulb 75 0
NOTE: The above wattage figures are estimates. Try to check the wattage listed on your
electrical device before consulting this chart.
Figure 10- Estimated wattage requirements of common electrical devices.
Once you have determined what electrical devices you will be powering with the
generator, connect these devices according to the following procedure:
1. Plug in each electrical device with the device turned off.
NOTE: Be sure to attach appliances to the correct receptacle (outlet). Connect
standard 120 Volt, single phase, 60 Hz loads only to the 120 Volt receptacle.
Connect 120/240 Volt, single phase, 60Hz loads with a NEMA L14-30 plug only
to the 120/240 Volt receptacle See Figure 11 for a depiction of each of these
receptacles.
2. Switch the circuit breaker to the "on" position.
3. Turn on the connected electrical devices in the order of the amount of power they
require beginning with the device with the highest rated wattage requirement.
16
CAUTION: Do not connect 50Hz or 3-phase loads to the generator.
Figure 11- Receptacles available on the generator
SOME NOTES ABOUT POWER CORDS
Long or thin cords can drain the power provided to an electrical device by the generator.
When using such cords, allow for a slightly higher rated wattage requirement by the
electrical device. See Figure 12 for recommended cords based on the power requirement
of the electrical device.
Device Requirements
Amps Watts (120V)
2.5 300
5 600
7.5 900
10 1200
15 1800
20 2400
25 3000
30 3600
40 4800
*NR= not recommended
Watts(240 V)
600
1200
1800
2400
3600
4800
6000
7200
9600
#8 wire
NR
NR
NR
NR
NR
175
150
125
90
Max. Cord Length (ft) by Wire Gauge
#10 wire #12 wire #14 wire #16 wire
1000 600 375 250
500 300 200 125
350 200 125 100
250 150 100 50
150 100 65 N R
125 75 50 NR
100 60 NR NR
65 NR NR NR
NR NR NR NR
Figure 12- Maximum Extension Cord Lengths by Power Requirement
DC Usage
CAUTION: The DC receptacle is for recharging 12 Volt automotive-type batteries
only. Do not connect any other device to this receptacle.
17
CAUTION: Use the generator only to recharge 12 Volt batteries. Never try to
jumpstart a car with your generator.
To connect 12 Volt batteries to the DC receptacle:
1. Connect one charging wire to the positive terminal on the battery and the other
charging wire to the negative terminal.
2. Connect the free end of the positive wire to the positive receptacle (outlet) on the
generator.
3. Start the generator.
4. Carefully connect the free end of the negative wire to the negative receptacle on
the generator.
5. When disconnecting, always disconnect the wires from the generator first to avoid
a spark.
ADANGER: Storage batteries emit highly explosive hydrogen gas when charged.
Batteries also contain acid, which can cause severe chemical burns.
•Do not allow open flames or cigarettes nearby for several minutes after
charging a battery.
•Always wear protective goggles and rubber gloves when charging a battery.
If battery acid gets on your skin, flush with water.
If battery acid gets in your eyes, flush with water and call a physician
immediately.
If battery acid is swallowed, drink large quantities of milk and call a
physician immediately.
STOPPING THE GENERATOR
To stop the generator:
1. Turn off, then unplug all connected electrical devices.
2. Switch the circuit breaker to the "off' position.
3. Allow the generator to run for several more minutes with no electrical devices
connected. This helps stabilize the temperature of the generator.
4. Set the engine switch to the "off' position.
5. Turn the fuel valve to the "off' position.
A WARNING: Allow the generator to cool for several minutes before touching
areas that become hot during use.
CAUTION: Allowing gas to sit in the generator tank for long periods of time
without use can make it difficult to start the generator in the future. Never store
generator for extended periods of time with fuel in the tank.
18
MAINTENANCE/CARE
Proper routine maintenance of your generator will help prolong the life of your machine.
Please perform maintenance checks and operations according the schedule in figure 13.
O If you have questions about any of the maintenance procedures listed in this manual,
please call (888) 315-3080 M-F 8-5CT.
CAUTION: Never perform maintenance operations while the generator is running.
Recommended Maintenance Schedule
every 3every 6
every month months or months or every year
each use or 20 hrs 50 hrs 100 hrs or 300 hrs
Engine oil _heck level x
"eplace x
Air cleaner sheck x
slean x
fuel filter cup slean x
spark plu_l sheck/clean x
gas tank sheck gas level x
slean x
Figure 13- Recommended maintenance schedule
Cleaning the Generator
Always try to use your generator in a cool dry place. However, in the event your
generator becomes dirty you may clean the exterior with one or more of the following:
a damp cloth
a soft brush
a vacuum
pressurized air
Never clean your generator with a bucket of water or a hose. Water can get inside the
working parts of the generator and cause a short circuit or corrosion.
Checking the Oil
The generator is equipped with an automatic shutoff to protect it from running on low oil.
Nonetheless, you should check the oil level of the generator before each use to ensure
that the generator crankcase has a sufficient amount. To check the oil level:
1. Make sure the generator is on a level surface.
2. Unscrew the oil filler/dipstick cap (see figure 14).
3. With a dry cloth, wipe the oil off of the stick on the inside of the cap.
4. Insert the dipstick as if you were replacing the cap and then remove again. There
should now be oil on the stick. If there is no oil on the stick, or oil only at the
19
.
very end of the stick, you should add oil until the engine crankcase is filled. See
"Changing/Adding Oil" in this section.
Be sure to replace cap when finished checking oil.
Figure 14- Checking the oil
Changing/Adding Oil
You should check the oil level of your generator according to the maintenance schedule
in figure 13. When the oil level is low you will need to add oil until the level is sufficient
to run the generator.
The oil capacity of your generator engine is listed in figure 15.
Model number
Engine oil
capacity
2200 3500
20 fluid oz. 20 fluid oz.
5500
37 fluid oz.
Figure 15- Engine Oil Capacity.
It is only necessary to drain the oil from the crankcase if it has become contaminated with
water or dirt. In this case, you can drain the oil from the generator according to the
following steps:
1. Place a bucket underneath the generator to catch oil as it drains.
2. Using a 10 mm hex wrench, unscrew the oil drain plug, which is located on the
crankcase underneath the oil filler/dipstick cap (see figure 16). Allow all the oil to
drain from the generator.
3. Replace the oil drain plug and tighten with a 10 mm hex wrench.
To add
1.
2.
3.
oil to the crankcase, follow these steps:
Make sure the generator is on a level surface.
Unscrew the oil filler/dipstick cap from the engine as shown in figure 15 above.
Using a funnel, add high detergent motor oil to the crankcase. We recommend
SAE 10W/30 motor oil for general use. When full, the oil level should come close
to the top of the oil fill opening (see figure 17).
2O
DRAIN PLUG
Figure 16- Draining oil Figure 17- Adding oil
NOTE: Never dispose of used motor oil in the trash or down adrain. Please call
your local recycling center or auto garage to arrange oil disposal.
Air Cleaner Maintenance
Routine maintenance of the air cleaner helps maintain proper air flow to the carburetor.
Occasionally check that the air cleaner is free of excessive dirt.
1. Unhinge the clasps at the top and bottom of the air cleaner cover (see figure 18).
2. Remove the sponge-like elements from the casing.
3. Wipe the dirt from inside the empty air cleaner casing
4. Wash the sponge-like elements in household detergent and warm water. Allow to
dry.
5. Soak the dry elements in engine oil. Squeeze out any excess oil.
6. Replace the sponge-like elements in the air cleaner casing and replace the cover.
COVER
SPR_NG A_R CLEANER
COVER
ELEMENT
...........
'"', g', 77{t_%÷_T<_& *
gQ* _ g*
v {,, i ¢*%{
, g ]
f
COVER
SPR_NG
Figure 18- Removing the air cleaner casing.
21
Fuel Filter Cup Cleaning
The fuel filter cup is asmall well underneath the fuel valve. It helps to trap dirt and water
that may be in your fuel tank before it can enter the engine. To clean the fuel filter cup:
1. Turn the fuel valve to the "off' position.
2. Unscrew the fuel filter cup from the fuel valve using a wrench. Turn the valve
toward you to unscrew (see figure 19).
3. Clean the cup of all sediment. Using a rag or brush.
4. Reinstall the fuel filter cup.
FUEL VALVE
FUEL FILTER CUP
Figure 19- Removing the Fuel Filter Cup
Spark Plug Maintenance
The spark plug is important for proper engine operation. A good spark plug should be
intact, free of deposits, and properly gapped. To inspect you spark plug:
1. Pull on the spark plug cap to remove it.
2. Unscrew the spark plug from the generator using the spark plug wrench included
with this product (see figure 20).
3. Visually inspect the spark plug. If it is cracked or chipped, discard and replace
with a new spark plug. We recommend using a F6RTC spark plug such as NGK
BPR5ES.
4. Measure the plug gap with a gauge (see figure 21). The gap should be 0.7-0.8mm
(0.028-0.03 lin).
5. If you are re-using the spark plug, use a wire brush to clean any dirt from around
the spark plug base and then re-gap the spark plug..
6. Screw the spark plug back into its place on the generator using the spark plug
wrench. Replace the spark plug cap.
22
PLUG CAP
PLUG W_ENOH
O, 7@, 8 !_>
_{_ z:, (00260031 n;
Figure 20- Removing the spark plug Figure 21- Measuring the spark plug gap
Emptying the Gas Tank
Before storing your generator for extended periods of time, you should drain your
generator of gasoline. To drain the generator of gas:
1. Turn the fuel valve to the "off' position.
2. Remove the fuel filter cup (see "Removing the Fuel Filter Cup" earlier in this
section.
3. Empty the fuel filter cup of any fuel.
4. With a receptacle underneath the generator to catch the gas, turn the fuel valve to
the "on" position. Drain all the gas from the generator.
5. Turn the fuel valve to the "off' position.
6. Replace the fuel filter cup.
7. Store the emptied gasoline in a suitable place.
A CAUTION: Do not store fuel from one season to another.
STORAGE /TRANSPORT PROCEDURES
A CAUTION: Never place any type of storage cover on the generator while it is
still hot.
When transporting or storing your generator for extended periods of time:
• Empty the gas tank (see "Elnptying the Gas Tank" in the "Maintenance"
section).
• Disconnect the spark plug.
• Do not obstruct any ventilation openings.
• Keep the generator in a cool dry area.
23
SPECIFICATIONS
Generator
AC Output
model2200 model3500 model5500
R_edW_tage 1800W 3000W 5000W
_urgeW_tage 2200W 3500W 5500W
R_ed Voltage 120/240 V 120/240 V 120/240 V
R_ed Amperage 15 A/7.5A 25 A/12.5A 41A/20.5A
R_ed Frequency 60Hz 60Hz 60Hz
Phase Single Single Single
DC Output
model 2200 model 3500 model 5500
Voltage 12V 12V 12V
Amperage 8.3 A 8.3 A 8.3 A
Dimensions(in): length = 23.25 width = 17 length = 23.25 width = length = 27 width=20
height = 17 17 height = 17 height = 21
Dry mass 99 lbs 99 lbs 168 lbs
model 2200 model 3500 model 5500
Engine type 4-stroke OHVsingle 4-stroke OHVsingle 4-stroke OHVsingle
cylinder with forced air =ylinder with forced air cylinder with forced air
cooling system =ooling system cooling system
[gnition system non-contact transistor non-contact transistor non-contact transistor
Displacement 163 cm 3 196cm 3 337cm 3
Fuel tank 15 L (3.96 US gal.) 15 L (3.96 US gal.) 25 L (6.60 US gal.)
zapacity:
Dil capacity 0.6 L (20 fl oz.) 0.6 L (20 fl oz.) 1.1 L (37 fl oz.)
Run time on 50% 21 hrs 15 hrs 15 hrs
Load
24
TROUBLESHOOTING
IMPORTANT: If trouble persists please call our customer help line at (888) 315-3080
M-F 8-5.
Problem
Engine will not
start
Engine runs but
there is no
electrical output
Generator runs bul
does not support
all electrical
devices
connected.
Cause
Engine switch is set
LO"Off".
Fuel valve is turned
Lo"closed".
Shoke is open.
Engine is out of gas.
Engine is filled with
sontaminated or old
gas
Spark plug is dirty.
Spark plug is
3roken.
Generator is not on
evel surface.
:Dilis low
Sircuit breaker is off.
Bad connecting
Mres/cables.
Bad electrical device
sonnected to
generator.
Generator is
3verloaded
Short in one of the
sonnected devices.
_,ir cleaner is dirty.
Solution
Set engine switch to "on".
Turn fuel valve to "open" position.
Close the choke
&dd gas.
Change the gas in the engine.
Clean spark plug.
Replace spark plug.
Move generator to a level surface to prevent low oil shutdown
from triggering.
Add or replace oil.
Set the circuit breaker to the "on" position.
If you are using an extension cord, try a different one.
Try connecting a different device.
Try connecting fewer electrical loads to the generator.
Fry disconnecting any faulty or short-circuited electrical loads.
Clean or replace air cleaner.
25
b_
I
fret11
1
2
3
.,I
5
6
7
8
9
i0
ii
12
13
i,'I
15
16
17
18
19
20
21
22
23
2,'I
25
26
27
28
29
3O
31
32
33
3d
Part
41100
41310
41320
GB6177 86
GB802 88
41350
GB5787 86
41116
32520
32100
32310
35510
GB5787 86
37300
37310
37321
68511
68512
35410
37420
31710
GB5787 86
GB6187 86
GBS19 85
32115
32116
31200
31936
31100
31370
31411
31938
31995
Oty DescriiKion
Gasoline engine
1 Frame comp
2Bottom rubber A
2Bottom rubber B
8 Flange nut M8
Nut M6
t Cushion, frame
t Bolt M6X 12
1 Rubber pad, frame
1 Earth terminal set
1 Wire harness Assy
1 Switch wire
1 Consent (30A)
3 Bolt M4X i0
1 Control panel Assy
1 Control panel
1 Control panel case
1 Panel switch mark,RH
1 Panel switch mark,LH
1 Ignition switch
1 Voltmeter
1 Circuit protector (10A)
Flange bolt M6 X 12
2Nut M4
2Pan screw M4 X 10
1 Boot, AC output wire
1 Boot, main wire harness
1 Stator Assy
1 Stator cover
1 Rotor comp.
1 Brush Assy
1 Generator stay
1 Generator end cover
3 Bolt M5 X 12
Item Part
35 31600
36 GB276 89
37 31134
38 31931
39 31933
40 31141
41 31996
42 30100
43 16610
44 16500
45 16521
46 16916
47 37820
48 GB819 85
49 GB5787 86
50 16821
51 16811
16931
52
53 16937/168F
54 16930
55 16812
56 1682,t
57 37825
58 18300/168F BV
59 18611
60 GB5787 86
61 18110/168F BV
62 18221/168F BV
63 18720
64 18710
65 GB5787 86
66 GB6187 86
67 GB5787 86
68 12255/168F
Oty Description
1 Voltage regulator
1 Bearing 6202-2RS
1 Plain washer
,t Flange bolt M6 X 125
1 Bolt M8X 180
1 Generator t:an
8 Bolt M5 X 14
1 Stator & rotor Assy
1 Fuel tank
1 Fuel filler cap comp.
1 Packing ring
1 Fuel filter
1 Fuel sensor
2 Screw M5 X 10
4 Flange bolt M6 X 22
4 Washer
4 Cushion
1 Outlet pipe
(1,9x d),t. 5x 130
2Tube clip
1 Fuel cock
1 Stripe, fuel tank
,t Fitting brush, fuel tank
1 Gasket, fuel sensor
1 Muffler
1 Muffler guard
3 Flange bolt M8 X 16
1 Exhaust pipe comp.
1 Muffler gasket
1 Supporting plate
1 Muffler stay
2 Bolt M8 X 25
2Nut M8
6 Flange bolt M6 X 12
1 Exhaust pipe gasket
27
Main col! 1
_ain coi! 2
Excitatio_ coil
Field col
BCcoil
GENERtTORBLOCK
Br (_ Br
R ©
vO
BREAKER
q-,
L
CONTROLPANELBLOCK
AC 120V,2_0V
Bu
_'I_ AVR
FUSE R
YiO
ENGINEBLOCK
Spark piub
ENGSWITEH
BL
Ignition coil Fuel level switch
ENGSWITEH
KG E
OFF (_ @
ON
BL Black R red
Y yellow W write
BU blue Br Brown
6 green
13
13
NOTES:
29

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